Top load cartoner

ABSTRACT

A cartoning method including the steps of: feeding blanks from a single magazine through a single blank feeder in a first direction; forming an array of at least two blanks from the fed blanks and thereafter transporting the array for forming, loading and closing via respective robot kinetics of at least two axis motion. Carton blanks and cartons travel through a path. Robots below the path transport the cartons. Robots above the path facilitate carton forming, loading and closing. Methods and apparatus are disclosed.

PRIORITY CLAIM

Applicant claims the benefit of the filing date of Mar. 3, 2006 of U.S. provisional patent application Ser. No. 60/779,111 and of the filing date of Oct. 24, 2006 of U.S. provisional patent application Ser. No. 60/854,023, both of the same title as this utility application and both herewith expressly incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to cartoners and more particularly to cartoners capable of loading items into cartons or trays through the carton or tray top, rather than from its end or side.

BACKGROUND OF THE INVENTION

Traditional cartoners are generally designed to load cartons from the end or side, where items are pushed into an erected carton and thereafter side or end flaps are glued and closed to finish.

There have been several attempts at top loading cartons or trays with items. In these devices, portions of a flat carton or tray blank, are glued up or a lock mechanism is used to form an open carton or tray which is then loaded from the top. Alternately, the blank is partially formed around an item or group of items placed on the blank, such as in a wraparound process.

Presently, the industry desires to accomplish a variety of packaging formats for a variety of products, and to do so on a single, relative low cost cartoner, with minimal change parts or modules and changeover downtime for different package configurations or size. In this regard, it will be appreciated that packaging machines, such as cartoners, typically operate either continuously or intermittently. That is, the equipment continuously moves items and packages or cartons through a process where they are combined, or the equipment operates intermittently to this end.

Advantages of an intermittent cartoner are typically lower cost, smaller machine footprint and accommodation of many load building and load configuration options. Advantages of a continuous motion cartoner, among others, are high speeds and operational benefits in product loading. The choice of one or the other of these operating processes is typically made at the expense of losing one or more advantages of the other.

Accordingly, one objective of the invention has been to provide a top loading carton apparatus capable of loading items into a variety of package or carton formats and utilizing advantages of both continuous and intermittent cartoning processes.

In another aspect of the cartoning process, it will be appreciated that typical cartoners of the past traditionally erect and convey cartons on a fixed pitch spacing. For example, cartons are conveyed by chain-driven lugs at fixed distances with respect to each other throughout the carton erecting, loading, gluing, closing and discharge operations. Such fixed pitch equipment can be adjusted to different pitch, but this requires downtime, not only in the adjustment of carton conveying lugs but in changeover and adjustment of associated equipment such as loaders, gluers, closers and the like.

Accordingly, it is another objective of the invention to provide a cartoner which is pitchless, that is a cartoner which can handle a variety of blank formats and sizes without regard to pitch (or spacing therebetween) and being easily programmed and adjusted for a wide variety of carton types and spacing, and with minimal downtime and changeover parts.

A further objective of the invention has been to provide an improved top loading cartoner.

SUMMARY OF THE INVENTION

To these ends, the invention contemplates a cartoner with a unique combination of elements and functions which facilitate the mixing and matching of both continuous and intermittent operations wherever in the process these operations are most beneficial or advantageous. Such operations are carried out sequentially or simultaneously in any desired mix and independently of the nature of an operation in another part of the cartoning process. The invention, in one aspect, contemplates the use of tooling for holding cartons or trays while continuous or intermittent processes as desired are carried out on them. As an example, at least two separately programmable transport robots handle cartons or trays with intermediate tooling. And “Z” or vertical axis motion can be used for particular carton processes.

More particularly, the invention contemplates, in at least one embodiment, a cartoner having a single carton blank feeder (as opposed to multiple feeders) preferably fed by a single blank magazine and for depositing through a single feed point one or a group of cartons on a feeder conveyor. The interaction of the timing of the blank feeder and of the feeder conveyor sets the spacing or pitch between carton blanks on the feed conveyor.

A robot disposed above the cartons, and provided, for example, with vacuum tooling, picks up the cartons and in this embodiment moves them through a glue area (as required), and a die area where the blanks are formed into trays or cartons with open tops.

Another robot, disposed beneath a carton path is provided with tooling to then receive and transport a batch of the formed cartons from the forming area to a load area. During this transport, the carton pitch can, if desired, be closed up by the robot with the cartons moved closer together.

The batch of formed cartons is loaded through open tops by yet a third robot. Thereafter, the cartons are moved to a glue and/or closing station by yet a fourth robot from where the completed trays or cartons are discharged.

In summary in one embodiment, the feeding and forming steps are carried out continuously, in single stream form with arrays of blanks, the loading is performed intermittently and the gluing and closing continuously, with carton pitch varying as desired during the process. Adjunct tooling, elements and the like can be used to operate on or with the cartons or trays as they are held within the end of arm tooling of the robots. For example, pitch of the cartons can be changed.

The invention is facilitated by a unique combination of robots disposed both above and below the carton path, each provided with tooling to handle, form or load cartons or trays through segments of the operation.

It will be appreciated that the operation on the blanks, and the cartons or trays formed from them, are carried out in the various stages of the carton in either continuous or intermittent fashion, depending on which format is most advantageous for the particular operation, and quite independent of the operational format used in other stages of the cartoning process. Thus smaller footprint, product loading and carton specific operations are provided and enhanced, producing a cartoning operation with benefits of both continuous and intermittent motion, and all in a pitchless or pitch varying process. The unique combination of robots oriented for transport below the cartons, combined with robots oriented above the cartons for forming and loading, produce unique and significant results in a top loading cartoner of the invention.

In another embodiment, carton blanks are fed from a single magazine through a single feeder, but are glued as, or just after, they are fed so that an array of glued cartons is provided and there is no need for another glue area or station operating on the array of blanks as in the above embodiment.

It will be appreciated that there is no need in the invention for multiple carton feeders or feeder magazines (even though multiple feeders could be used), thus leaving open a side of the cartoner where such multiple units would otherwise block access.

Use of two or more lower robots beneath the cartoner for carton transport can accommodate whole or half tooling with sufficient clearance or programming control so tooling interference at higher speeds are avoided.

Moreover, it will be appreciated the invention includes the process of forming an array of blanks from a single magazine and feeding blanks into an array through a single infeed point. Also, a process according to the invention includes transporting the blanks between forming and loading stations and between loading and closing stations using a two-axis motion or robotic mechanism.

These and other objectives and advantages of the invention will be readily appreciated from the foregoing, and from the following written description and drawings, in which:

Brief Description of the Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention.

FIG. 1 is an illustrative perspective view of one cartoner embodiment according to the invention;

FIG. 2 is a diagrammatic flow chart of the operation of the cartoner in FIG. 1;

FIGS. 3A and 3B are illustrative views of a variety of one form of carton or tray or sleeve sizes and shapes which can be formed and loaded on the cartoners of FIGS. 1-2;

FIG. 4A is an illustrative view of one robot assembly operating below the carton path of the cartoner in FIGS. 1-2;

FIG. 4B is an end elevational view taken along lines 4B-4B of FIG. 4A;

FIG. 5 is a perspective view of a cartoner according to the invention illustrating use of an under carton path robot of FIGS. 4A and 4B in the carton forming, loading and closing area of the cartoner;

FIG. 6 is a perspective view of an overhead robot of the type used in forming or in loading of cartons according to the invention;

FIG. 7 is a perspective illustration of a carton blank feeder for feeding cartons at selected pitch for forming and loading according to the invention;

FIG. 8 is a perspective illustration of the loading area of the invention as in FIGS. 1-2 but illustrating an alternate orientation of two robots in the loading area, each separately programmable for performing desired loading functions;

FIGS. 9-20 are respective perspective views illustrating a sequence of operations or features of a cartoner embodiment according to the invention;

FIG. 21 is a perspective view illustrating an alternate embodiment of the invention where four transport robots are used to produce a higher product through-put speed;

FIGS. 22-28 are respective perspective views illustrating a sequence of operations of another cartoner embodiment according to the invention, particularly adapted to handling product containing sleeve-type packages;

FIG. 29 is an illustrative perspective view of an alternate cartoner embodiment according to the invention, with like parts to the embodiment of FIG. 1 numbered similarly;

FIG. 30 is a diagrammatic flow chart of the operation of the cartoner of FIG. 29;

FIGS. 31-38 are illustrative drawings showing features of the alternative embodiment features of FIGS. 29 and 30 and are further described;

FIG. 31 is a view looking upstream and shows the carton blank magazine(with feed omitted for clarity), with the reciprocal suction cup platform for raising to receive fed blanks and for lowering to place them on vacuum belts in the foreground of the drawing;

FIG. 32 is a view looking upstream and illustrates the carton magazine and the downstream glue guns;

FIG. 33 is a view looking downstream, showing the glue guns, the blank receiving area on the vacuum belts and the former robot;

FIG. 34 is a view looking across the vacuum belts and shows a fed but yet unglued blank;

FIG. 35 is a view showing a second sequentially fed blank, with a first downstream blank approaching the glue station from left-to-right;

FIG. 36 is a view similar to FIG. 35 but showing a third sequentially fed blank with the first downstream blank having passed the glue station and the second blank approaching the glue station;

FIG. 37 is a view showing an array of three glued blanks, ready for picking by a robot for transfer to former tooling; and

FIG. 38 is a view showing the array of three glued blanks as in FIG. 37 but from the opposite direction of FIG. 40 and also shows the former tooling area to which the array will be transferred.

Detailed Description

Turning to the drawings, and particularly FIGS. 1-3B, it will be appreciated that the invention in one embodiment is capable of top loading a variety of open-top cartons or trays 10 as illustratively depicted in different sizes in FIGS. 3A and 3B. While cartons 10 are specifically shown, it will be appreciated that trays, sleeves and other forms of packaging can be handled according to the invention.

FIG. 3A illustrates a variety of the flat carton blanks 10 in open or developed configuration while FIG. 3B illustrates the varied open top cartons 10 of FIG. 3A but in erected configuration, with open top and side flaps, ready for loading of items through the open tops shown. Various cartons are depicted in FIGS. 3A and 3B in overlaid form for clarity to illustrate the variety of sizes of one carton format which can be handled in the cartoner of the invention. Other carton, tray and sleeve formats can be handled as well and reference to cartons herein is not meant to limit the scope of the invention.

FIGS. 1-2 illustrate diagrammatically features (FIGS. 1-2) and the operational process (FIG. 2) of one embodiment of the invention as a top loading cartoner 14. The invention is clearly understood by the following description of a sequence of operation of the invention and of its features.

The overall process and apparatus of this embodiment are best seen in FIGS. 1-2, however, reference is also to the sequence illustrated in FIGS. 9-21 and to FIGS. 22-28 as appropriate. A reciprocating feeder pick-arm pulls a single blank B from the horizontal magazine 18 and positions the blank B on the feed conveyors 19 in a feed conveyor area.

As the reciprocating feed arm 17 returns to get the next blank B, the feed conveyor 19 advances in a first direction forward one station to prepare to receive the next blank B.

The process continues until the count of blanks B for the machine set-up is achieved (i.e., usually 2 to 6 blanks), these blanks forming an “array” of blanks. The feed conveyor 19 incorporates additional features such as vacuum hold down, that provide hold-down and positioning capability for the blanks. Four blanks in an array are shown for clarity here.

As used herein, an “array” of blanks describes a group of two or more blanks on which operations can be performed simultaneously. In other embodiments, an “array” could simply describe a blank group.

Once the last blank B (the fourth blank B of FIGS. 1 and 2) is received into the feed conveyor area and moved into position, the overhead Former Robot 22 engages all of the arrayed blanks simultaneously with its vacuum tooling 23, which may be of any suitable construction.

Having received a signal that vacuum has been achieved at each blank B, the Former Robot raises vertically a short distance to disengage from the feed conveyor area 19 and then begins a horizontal move in the direction of arrow 54 perpendicular to the longitudinal flow of the original blank flow stream in the first direction (see the “Position” to “Glue” step of FIG. 2).

Having moved away from the feed conveyor 19, the Former Robot passes the array of four carton blanks being carried in a second perpendicular direction over a stationary glue gun region 26 (when needed). Multiple glue guns shoot upward to apply glue at the appropriate positions on the blanks B. It is understood glue may or may not be required at this time.

Continuing the blank motion past the glue gun region 26 in the second direction, the Former Robot carries the array of four carton blanks B into position over the top of the forming or closing die area 28, comprising a plurality of closing dies (not shown in detail).

The Former Robot 22 then plunges the array of carton blanks B preferably downward through individual forming dies to produce the bottom shape of cartons. Depending on the machine set-up, the Former Robot will then either release the open top cartons C at the bottom of the Former Robot stroke, as it hands-off to the below mounted Former-to-Loader Transport Robot 30, or alternately return upward back out the top of the forming dies with the cartons C. If the second approach is used, the Former Robot then moves horizontally an additional distance and then lowers to make the hand-off of cartons to the below mounted Former-to-Loader Transport Robot 30.

Having successfully made the hand-off, the Former Robot 22 returns to the feed conveyor area 19 to repeat its cycle while the Former-to-Loader Transport Robot 30 moves horizontally (perpendicular to the Former Robot flow, see FIG. 2) toward the loading area 32.

When the Former-to-Loader Transport Robot 30 arrives in the loading area 32, it stops at the handoff station 33 that engages the cartons C via vacuum to hold the carton positions for the loading process and then subsequent pick-up by the Loader-to-Closing Transport Robot 36.

Once the handoff station 33 has engaged the carton array, the Former-to-Loader Transport Robot 30 lowers slightly downward away from the carton array and then returns back to repeat its cycle. While the Former-to-Loader Transport Robot 30 is returning, the overhead Loader Robot 38 can begin the loading process at the loading area. Various types of suitable robots can be utilized in the loading area, such as an: Overhead Two-axis Robot, SCARA, Six-axis, etc. or any other suitable Robot kinematic can be used. As well, any suitable Robots combined or oriented as described herein may be found useful in the invention.

Having previously picked up the appropriate quantity and configuration of products (not shown) from a product infeed system 40 with its tooling, the Loading Robot 38 is ready to insert the product into the cartons C once they are engaged by the handoff station 33. Depending on the machine set-up, product requirements, and product infeed design, the Loader Robot 38 can pick-up and place multiple cartons' worth of product during each move or alternately fill each of the cartons C individually (even if an array of cartons is being processed through other parts of the machine).

While the loading process is taking place and after the Former-to-Loader Transport Robot 30 disengaged and has started to move away from the handoff station, the Loader-to-Closing Transport Robot 36 can move into position under the carton array in the handoff station 33 and engage the cartons C with its tooling.

When the loading process is complete, the Loader-to-Closing Transport Robot 36 can begin to move horizontally away from the handoff station 33 toward the closing and discharge section 42.

Enroute to the closing area 42 of the machine 14, the Loader-to-Closing Transport Robot 36 carries the carton array past an optional gluing station 44 provided with glue guns (not shown) for glue application to the carton top flaps F. Prior to aligning with the glue guns, the cartons C individually engage fixed guide-work (not shown) that bend the flaps F into proper position to receive the glue.

After the glue is applied, the Loader-to-Closing Transport Robot 36, having never stopped its horizontal motion, continues to carry the carton array past fixed guide-work (not shown) that further moves the flaps into position for final closing.

Having arrived at the closing section 42, the Loader-to-Closing Transport Robot 36 stops its horizontal motion and then moves vertically, pushing the cartons upward through individual stationary dies (not shown). The stationary dies push the carton flaps closed and compress the glue, producing the completed cartons at the top of the Loader-to-Closing Transport Robot up-stroke.

The Loader-to-Closing Transport Robot 36 tooling releases its hold on the cartons and allows a cross-pusher (not shown)of any suitable construction, working perpendicular to the Loader-to-Closing Transport Robot 36 flow, to move the carton array horizontally onto a discharge conveyor (not shown) that carries the cartons out of the machine 14 perpendicular to the flow of the cross-pusher, i.e. in the direction of the machine flow MF or alternately perpendicular thereto.

The Loader-to-Closing Transport Robot 36 retracts downward after the cross-pusher's initial actuation and returns to the handoff station 33 at the appropriate time to repeat its cycle.

With reference to FIG. 2, it will be appreciated that various steps and operations of this embodiment of the invention are represented in the flowchart, and numbers corresponding to the Robots described have been illustratively provided to the appropriate steps in the chart of FIG. 2. In particular, initial array handling and carton forming is facilitated by the Former Robot 22. Carton array transport is facilitated by Former-to-Loader Transport Robot 30, carton loading is facilitated by Loader Robot 38 and carton transport from loading to discharge is facilitated by Loader-to-Closing Robot 36.

It will be appreciated that the flow steps illustrated in FIG. 2 correspond in direction with the top plan view of cartoner 14 showing the flow of cartons and carton arrays.

It will be further appreciated that Robots 22 and 38 are oriented generally above the plane of carton movement through cartoner 14, while the respective transport robots are oriented below the plan of carton movement through cartoner 14. Each may be respectively provided not only with X-Y translation, but vertical or “Z-axis” translation as well.

Various features of the invention are shown further in FIGS. 4A through FIG. 8. In FIG. 4A, a representative robot 30, 36 is shown having a head 48 to which can be mounted appropriate end-of-arm tooling for handling the respective blanks and cartons for transport. Robots 30, 36 are respectively oriented beneath the plane of carton movement, and are preferably offset (see FIG. 1) for handling cartons as described above. Appropriate tooling is of suitable configuration such that the respective paths in which the tooling moves are sufficiently separate to accommodate desired machine speed without tooling interference from one robot=s tooling with that of another robot.

FIG. 5 illustrates the parallel orientation of two transport robots 30, 36 from the rear side of cartoner 14 where the machine flow is to the left. See also FIG. 20 in this regard, viewed from the front side of the machine.

FIG. 6 illustratively depicts overhead robots such as Former Robot 22 and Loader Robot 38. These may be mounted to appropriate stationary or even moveable frames as desired. Each has a head 54 on which can be secured the appropriate tooling to handle blanks B and cartons C respectively (Robot 22) on the appropriate products for loading (Robot 38). It will be appreciated that such tooling on Robot 22 can accommodate the number of blanks in an array, or a smaller number.

FIG. 7 illustrates the carton blank feed operation with a single horizontal blank feed magazine 18 illustratively depicted at 18 and feeding flat blanks to feed or picker 17 which lays individual blanks one at a time onto feed conveyors 19 (not shown in FIG. 7). Any suitable carton magazine and blank feeder can be utilized and it will be appreciated that only one is required. The blanks are depicted in arrays 50, 51 while at least partially formed cartons C are in array 52. Arrow 54 illustrates the direction of movement of array 50-52 as also illustrated in FIGS. 1 and 2. The arrays can be any practical number of cartons, set in count by the feeder 17.

FIG. 8 illustrates an alternate loading embodiment wherein overhead Robots 38 a and 39 b are used for loading products into cartons. It will be appreciated that one Robot 38 a (for example) can be used for loading. Two or more Robots 38 a, 38 b can be used to provide varied loading functions. In such a case, one Robot 38 a in the loading area can be a two-axis robot, while robot 38 b could be a four-axis robot, for example. Other combinations of robotic kinematics could be used.

It will be appreciated from FIGS. 1 and 5, for example, that the cartons in an array 52 can be repositioned with respect to each other so as to expand or, as shown, close up the spacing between cartons. Thus, the pitch of the cartons can be changed by any suitable mechanisms during the forming, loading and closing processes to accommodate and provide significant flexibility in the cartoning process. As perhaps best seen in FIG.1, the carton pitch has been closed up or shortened in the load area 66 where the carton C can be loaded with product through other open tops on an intermittent basis, without constraining the continuous motion of blanks or cartons at the feed area, or in the discharge area. This ability to operate on a pitchless basis and to use both continuous and intermittent motion in the same cartoning line provides unique advantages as mentioned above. Tooling, change out, end of arm tooling, end effectors or any other suit mechanisms can be used to facilitate these carton spacing changes as described.

FIGS. 9-20 illustrate a sequence of carton handling for one embodiment of the invention, and consistent with the foregoing description.

In FIG. 9, open top cartons C-1, C-2 have been handed off at forming station 32 to an end-of-arm tool 60 mounted on Former to Loader Transport Robot 30. Tooling 60 is any suitable tooling capable of handling and transporting cartons C-1, C-2 (just two cartons here are shown for clarity; the number can be one or more as practicable). Additional end-of-arm tooling 62 is mounted on the Loader-to Closing Transport Robot 36 for receiving cartons C-1, C-2 from tooling 60.

Tooling 60 defines carton positions 69, 70 in this embodiment, while tooling 62 defines carton positions 71, 72 thereon.

Also illustrated in FIG. 9 is tooling 64 oriented at loading station 66 for handling cartons C-1, C-2 at station 66. Tooling 64 can be stationery or can be vertically or horizontally reciprocated or tilted as desired.

Finally, with respect to FIG. 9, it is noted that tooling 60 is in a raised position to receive cartons C-1, C-2 from the Former Robot 22 (not shown in FIG. 9).

In FIG. 10, tooling 60 is lowered to initiate transport and transfer to the loading station 66.

FIG. 11 illustrates transport of cartons C-1, C-2 to loading station 66 defined in part by tooling 64. Tooling 62 has been moved by Loader-to-Closing Robot 36 downstream in the direction indicted by arrow MF.

FIG. 12 illustrates the positioning or setting of cartons C-1, C-2 at loading station 66, on tooling 64.

FIG. 13 illustrates:

a) the location of cartons C-1, C-2 on tooling 64;

b) withdrawal (arrow 74) of tooling 60 by Robot 30, alternately accompanied by a further lowering of tooling 60; and

c) raising of tooling 62 (arrow 76) to raise any cartons (not shown) which are thereon for final closing.

FIG. 14 illustrates both the full retraction of tooling 60 by Robot 30; positioning of cartons C-1, C-2 on tooling 64; and downward retraction or position of tooling 62 by Robot 36.

FIG. 15 illustrates raising of tooling 60 by Robot 30 to receive another set or array of formed cartons from Former Robot 22 (not shown); and the partial return of tooling 62 by Robot 36 beneath cartons C-1, C-2 which have been now filled by Overhead Loader Robot 38 (FIG. 1) while on tooling 64.

FIG. 16 illustrates the positioning of subsequent cartons C-3, C-4 on tooling 60 while cartons C-1, C-2 are either set prior to, during or after top loading at station 66.

FIG. 17 illustrates the lowering of tooling 60 by Robot 30 and cartons C-3, C-4 to a plane for transport to tooling 64 and the downstream movement of loaded cartons C-1, C-2 on tooling 62 by Robot 36, away from tooling 64. In this figure, carton C-2 also has moved past appropriate guides which fold flap F over into position for final closing. Glue can be applied to flap F in this area.

FIG. 18 illustrates transport of cartons C-3, C-4 into tooling 64 by tooling 60 of Robot 30. Cartons C-1, C-2 are now partially closed with flaps F over the cartons.

FIG. 19 illustrates positioning of cartons C-3, C-4 in tooling 64. Cartons C-1, C-2 are raised on tooling 62 by Robot 36 through closing dies for flap closing and discharge.

FIG. 20 diagrammatically illustrates the respective orientation of Robots 30, 36 with robot arms or heads 30 a and 36 b respectively, but with end-of-arm tooling removed for clarity;

FIG. 21 diagrammatically illustrates an alternate embodiment wherein four transport robots are used, in two sets of two each.

In particular, two transport robots 30, 31 facilitate the former-to-loader transport, similar to that described above, and two transport robots 36, 37 facilitate the loader-to-closer transport, also similar to that described above. However, it will be appreciated that robots 30, 31 each have end-of-arm tooling moveable in a partially common portion of respective “Z”shaped paths so that one transport robot 30 can be delivering cartons to tooling 64, while another transport robot 31 can be receiving cartons from the gluing and forming area.

Each robot 30, 31 has a head or arm 30 a, 31 a and end-of-arm tooling is mounted thereon. Each robot is capable of Z-axis or vertical movement so in translation, each is respectively raised or lowered as desired to prevent interference with the others as they pass or reset.

Similar construction and motion is provided by robots 36, 37 with respective arms 36 a, 37 a.

In this manner, it will be appreciated that throughput flow or speeds can be increased with various segments of former-to-loader or loader-to-closer transport taking place simultaneously.

More particularly, FIG. 21 illustrates the position of three carton arrays situated at various stages noted above in the foregoing figures, but wherein tooling 64 is fed or unloaded in this embodiment by additional robots 31, 37. Cartons C-1, C-2 have been closed, and are ready for discharge from robot 36 while robot 37 is moving to engage cartons C-4, C-3 on tooling 64. Cartons C-3, C-4 are in the loading position on tooling 64 and cartons C-5, C-6 are located after forming for transport by Former-to-Loader Transport Robot 31, all as discussed above.

In FIG. 21, robot arm 31 a is positioned to receive cartons C-5, C-6 from forming while robot 30 as delivered cartons C-3, C-4 to tooling 64. Robots 30, 31, 36, 37 are respectively disposed end-to-end rather than offset horizontally as in prior figures. Offset tooling and Z-axis motion cooperate to allow simultaneous operation of the associated robots continuously or intermittently.

Turning now to FIGS. 22-28, an alternative embodiment is illustrated wherein the invention is particularly adapted to the cartoning of multiple cups in sleeves such as in the cartoning of pudding, gelatin or the like. Such cups are packed in tandem rows in such sleeves with a bottom row extending through holes in the sleeve bottom and on upper row on top of the lower row and covered by said sleeve. In this embodiment, like elements bear the same numbers as previously disclosed in other embodiments.

It will be appreciated that arrays of four sleeve blanks 90-93 have been fed and formed through the use of the blank feed and Former Robot 22 of FIG. 1 to end-of-arm tooling 96 on Former-to-Loader Transport Robot 30. Each blank sleeve 90-93 is provided with cutouts for receiving product, such as sealed product cups.

Another blank array comprising four similar sleeve blanks 100-103 have been handed off to tooling 106 at loading station 108. Product cups 110 have been loaded onto respective blanks 100-103 as shown.

In FIG. 23, relative motion is created between blanks 100-103 and tooling 106 so the blank sleeve is folded up in partial wraparound of cups 110.

This operation is further illustrated with further sleeve folding in FIG. 24.

FIG. 25 illustrates further transport of sleeves 100-103. The sleeves 100-103 are picked up by suitable end-of-arm tooling 112 carried by Loader-to-Closer Robot 36. During this motion, appropriate guides or plows and glue applicators are used to fully close the sleeves 100-103 around cups 110.

FIG. 26 illustrates further transport of closed sleeves 100-103 downstream to a discharge station.

Cartons 100-103 are transported perpendicularly to the machine flow MF for discharge as illustrated in FIG. 27.

And in FIG. 26, the sleeves 100-103 have been discharged downstream in the direction MF. At the same time, subsequent cartons 90-93 are located in tooling for loading. While not shown in FIG. 28, tooling 96 may be returned by Robot 30 to receive a further array of blanks, such as in the position of tooling 96 in FIG. 22.

A further alternative embodiment of the invention is illustrated in FIGS. 29-38. In this embodiment, the structure and process is the same as previously described with the exception of the carton feeding, gluing of the blanks and subsequent grouping of a blank array prior to the downstream forming, filling, closing and discharge as described above.

Briefly, in this alternative embodiment, individual carton blanks 120-122 (FIGS. 29-38) in developed or flat condition are fed in a first direction from a single magazine 18 at an infeed point by any suitable blank feeder 17 onto a conveyor 19, preferably defined as a plurality of belts 123-125, which could be vacuum belts. A reciprocal suction cup platform 126 (FIG. 31) having a plurality of suction cups 127 is preferably raised between the belts 123-125 to receive the blanks and is lowered to deposit them, sequentially, on the vacuum belts 123-125.

From there, the blanks 120-122, (FIGS. 34-38) are conveyed sequentially in the first direction past one or more glue guns 128, 129 (FIG. 33), in this case two glue guns, at a glue station 28 a, where glue is selectively and sequentially applied to the blanks. After glue is applied, the blanks are conveyed to a blank array (see FIG. 38) formation area where a predetermined number of now glued blanks, such as the three blanks 120-122, are oriented in an array 130 of glued blanks.

From this position, the entire blank array 130 is picked by a suitable former robot such as robot 22 and is transferred in a second direction perpendicular to the first direction noted above to any suitable former tooling, such as tooling 23, where the blanks in the array 130 are preferably simultaneously formed into open-top trays for subsequent loading through their open tops, closing and discharge as previously described.

This embodiment of the invention thus provides for the grouping, in an array 130, of a predetermined number of blanks (120-122) fed sequentially from a single infeed point, feeder 17 or magazine 18, and provided with glue prior to further downstream operations and prior to formulation of an array of glued blanks.

Such apparatus can be used in a variety of cartoners where it is desired to define a plurality of blanks in an array for subsequent handling of any suitable nature such as described herein or in any other form of cartoning, whether or not as described herein.

It will be appreciated that the carton blanks can be continually fed to the vacuum belts sequentially, while the blanks in the formed array can be simultaneously moved into the former tooling in an intermittent fashion. Moreover, it will be appreciated that any traditional transport apparatus could be used to transfer the blanks, after forming, to and through further downstream cartoning operation.

In addition, further ancillary equipment (not shown) can be used to accomplish further tasks in the process, such as leaflet feeding into the trays, other loading techniques, other closing techniques, such as using an additional downstream robot 134 to accomplish tray closing, discharge and the like.

It will also be appreciated that FIG. 30 illustrates the overall process of this alternate embodiment. Moreover, while not shown in FIG. 30, the cartons or trays, after loading and before final closing, may be passed through a glue station where appropriate. Where the final cartons are not glued, but comprise “tuck” type tops, appropriate mechanisms as are well known can be used to tuck or close the cartons.

It will be further appreciated that this embodiment provides for and contemplates feeding blanks sequentially, from a single magazine and through a single infeed point, gluing blanks sequentially, thereafter forming an array of two or more glued blanks at an array station and transferring the array to a downstream station. Moreover, it will be appreciated that the blank feeding and blank movement through the gluing application is accomplished through movement of the blanks in a single direction or in the same direction, sequentially.

From this disclosure, it will also be appreciated that all the robot devices referred to herein, i.e. robots 22, 30, 36, 38, 80 and 82, for example, may comprise any suitable robot apparatus individually well known. More particularly, and whether or not technically qualifying as a robot, per se, this apparatus according to the invention preferably comprises at least a two axis programmable apparatus sufficient to produce the movements described herein (such as pick and place) and combined according to the invention.

It will be immediately appreciated from the foregoing that the invention provides several unique advantages. One such major advantage is the pitchless operation of the invention. In the embodiment of FIGS. 9-20, for example, carton arrays of two spaced cartons are handled. In the embodiment of FIGS. 22-28, four adjacent carton sleeves are handled. This is accomplished by change out of the end-of-arm tooling on the Robots 30, 36 and perhaps the tooling at the loading station proximate the intersection of the Robots 30, 36. Any change out is thus independent of, and does not require any transport lug changes, chain drive phasing or the like, and any carton or blank pitch can be accommodated by a simple, quick end-of-arm tooling change and Robot programming. This produces a single cartoner capable of handling a variety of carton sizes and formats, with little concern over carton pitch, or of machine design, restricted by associated equipment such as loaders, formers, product feeders, closers and discharge. One basic machine with relatively small number of change out parts can provide a manufacturer with a wide range of cartoning capability.

In this regard, and for example, it is possible with the invention to adapt a wide variety of loading mechanisms and functions for use with the invention without having to purchase or change out the entire cartoner.

Another aspect of the invention which produces these results is the unique combination of plural robots or two axis programmable apparatus in combined overhead and underneath disposition respecting the cartons. Use of overhead former and loading apparatus combined with underneath transport apparatus is thus highly advantageous in producing a multi-functional top load cartoner.

Moreover, the ability to use only a single blank feeder to provide blank arrays in multiple pitch for a variety of varied pitch carton formats comprises a significant advantage to cartoners where footprint, cost and adaptability are significant.

A significant advantage of the invention is the capacity to provide a cartoning machine and process with both continuous and intermittent operations in the same cartoning process and independently so the advantages of these operational formats can be used to obtain the beneficial aspects of each, as desired, without restriction by the operation of a separate process segment operating in a different format. Each operating segment including carton control, forming, transport, loading, closing and discharge can each be carried out continuously or intermittently, independently of and decoupled from other operational segments, providing beneficial cartoning and overall cartoning enhancement.

It will also be appreciated that it is possible to carry out procedures on the cartons while they are in motion between the specific stations described herein. In this regard, the arm end tooling holds and/or manipulates the cartons during their transport.

It will also be appreciated that in the embodiments disclosed, the blanks and formed trays or cartons are maintained under positive control throughout the process from blank feeding to loaded and closed tray discharge.

Finally, it will be appreciated that the carton blanks and cartons move through a path or a plane as they are fed, glued, formed, loaded, closed and discharged. The invention contemplates carton handling by transport robots oriented beneath the path or plane, and carton loading or other manipulation by robots or other multiple axis apparatus oriented above the path or plane. Such path or plane has a “thickness” or depth defined by the carton travel.

These and other advantages, embodiments and modifications will be readily apparent from the foregoing to those of ordinary skill in the art without departing from the scope of the invention and applicant intends to be bound only by the claims appended hereto. 

1. A cartoning method including the steps of: feeding blanks from a single magazine through a single blank feeder in a first direction; and forming an array of at least two blanks of predetermined number from said blanks.
 2. A method as in claim 1 including the step of: applying glue sequentially to cartons being fed from said feeder prior to the formation of said array.
 3. A method as in claim 1 including the step of: applying glue to said fed blanks after forming them into said array.
 4. A method as in claim 1 including the further step of: moving said array in a second direction perpendicular to the first direction in which carton blanks are fed from said feeder.
 5. A method as in claim 1 including transporting said array to a carton forming station and there at least partially forming cartons from said blanks in said array.
 6. A method as in claim 1 including the further steps of: transporting cartons from said carton forming station to a loading station and there loading items into said cartons; transporting loaded cartons to a closing station and closing loading cartons; and discharging cartons.
 7. A method as in claim 6 including transporting cartons from said carton forming station to said loading station by a robot having at least a two-axis motion.
 8. A method as in claim 6 including transporting cartons from said loading station to said closing station by a robot having at least a two-axis motion.
 9. A method of cartoning, including the forming, transporting and loading of cartons in selected carton arrays of two or more cartons, and including the steps of: feeding carton blanks onto a feed conveyor at a single infeed location from a single carton blank feeder; and forming an array of carton blanks on a feed conveyor by said feeding.
 10. A method of handling carton blanks and including the steps of: feeding carton blanks sequentially from a single infeed point; applying glue sequentially to said fed blanks; forming, at an array station, an array of blanks, having glue applied thereto; and transferring said array away from said array station.
 11. A method as in claim 9 wherein the steps of feeding and applying glue to said blanks includes moving said blanks in the same direction during said feeding and said glue applying.
 12. A method of cartoning wherein a plurality of operations are carried out on cartons and including the steps of conducting some of said operations in a continuous motion and some in an intermittent motion and wherein said motions are decoupled one from the other.
 13. A method of cartoning wherein products are loaded into cartons and including the steps of: forming cartons; transporting formed cartons to a loading station; loading cartons; and transporting cartons from said loading station; wherein at least one of said steps is carried out in continuous motion and another of said steps is carried out in intermittent motion and wherein said respective motions are decoupled one from the other.
 14. A method as in claim 13 wherein said forming, transporting and loading steps are all carried out by robots having at least two axes of motion and including the further step of selectively raising and lowering cartons with said robots during said cartoning.
 15. A method as in claim 13 including: engaging such cartons in end-of-arm tooling on a robot; and performing a carton manipulating operation on cartons while said cartons are engaged by said tooling.
 16. Apparatus for handling carton blanks, said apparatus including: a blank feeder defining a single infeed; a blank conveyor oriented to receive fed blanks from said single infeed and for transferring said blanks to a glue station; glue apparatus oriented to apply glue to blanks transported there-past; and an array orienting station downstream of said glue apparatus.
 17. Apparatus as in claim 16 and further including a blank receiving apparatus receiving fed blanks sequentially from said infeed and transferring fed blanks to said conveyor.
 18. Apparatus as in claim 16 wherein said blanks are fed sequentially onto said blank conveyor in a first direction, said conveyor oriented for moving said blanks in a single direction from said infeed past said glue apparatus.
 19. Apparatus as in claim 18 including transfer apparatus for moving an array of said blanks, downstream of said glue apparatus, in a second direction, perpendicular to said first direction, toward a carton forming station.
 20. A cartoner comprising: a former robot; a former-to-loader transport robot; a loader robot; and a loader-to-closer transport robot said robots operationally interconnected to form, transport, load and further transport loaded cartons.
 21. A cartoner as in claim 20 wherein said former and loader robots are oriented above a path of movement of said cartons and said respective transport robots are oriented below said path.
 22. A cartoner as in claim 21 further including end-of-arm tooling respectively carried by respective ones of said robots.
 23. A cartoner as in claim 22 further including at least two sets of end-of-arm tooling, each set facilitating loading of cartons oriented at a different pitch from cartons whose loading is facilitated by the other set.
 24. Cartoning apparatus comprising: a single magazine; a feeder for feeding blanks received from said single magazine in a first direction; a conveyor for receiving at least two blanks defining an array of blanks; and apparatus having motion in at least two axes for moving said array from said conveyor toward a carton forming apparatus.
 25. Apparatus as in claim 24 further including a robot for transporting an array of cartons from a carton former station to a carton loading station.
 26. Apparatus as in claim 25 wherein said robot is disposed beneath a path in which said array of cartons passes and said apparatus for moving said array from said conveyor toward a carton forming apparatus is disposed above said path.
 27. Apparatus as in claim 25 further including two robots for transporting an array of cartons from a carton former station to a carton loading station.
 28. Apparatus as in claim 24 further including a robot for transporting an array of cartons from a carton loading station to a carton closing station.
 29. Apparatus as in claim 28 further including a robot for loading items into said array of cartons and wherein said robot for transporting is disposed beneath a path in which said array of cartons moves and said robot for loading items is disposed above said path.
 30. Apparatus as in claim 27 further including two robots for transporting an array of cartons from a carton loading station to a carton closing station. 